TWR Lighting AA1-M User manual

4300 WINDFERN RD., SUITE 100 HOUSTON, TX 77041-8943
VOICE [phone] FAX [phone]
WEB: www.twrlighting.com
IMPORTANT!!!!
PLEASE TAKE THE TIME TO FILL OUT THE FORM COMPLETELY. FILE
IN A SAFE PLACE. IN THE EVENT YOU EXPERIENCE PROBLEMS WITH
OR HAVE QUESTIONS CONCERNING YOUR CONTROLLER, THE
FOLLOWING INFORMATION IS NECESSARY TO OBTAIN PROPER
SERVICE AND PARTS.
MODEL # ________AA1-M
SERIAL #
PURCHASE DATE
PURCHASED FROM

AA1-M CONTROLLER
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Oct 1998 Rev 06/02/99 – 09/10/99 – 05/27/00
Rev 03/31/03 (TWR Logo & reformatted)
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TABLE OF CONTENTS
1.0 GENERAL INFORMATION...............................................................................................4
2.0 INSTALLATION ................................................................................................................5
2.1 POWER SUPPLY CONTROL CABINET MOUNTING..........................................5
2.2 EXTERNAL PHOTOCELL WIRING ......................................................................6
2.3 POWER WIRING...................................................................................................6
2.4 RED BEACON, SIDELIGHT AND LOAD BALANCE RESISTOR WIRING...........6
2.5 RED BEACON AND SIDELIGHT ALARM WIRING...............................................7
3.0 THEORY OF OPERATION...............................................................................................9
3.1 THE POWER SUPPLY..........................................................................................9
3.2 THE SIDELIGHTS.................................................................................................9
3.3 BEACON ...............................................................................................................9
3.4 LOAD BALANCE RESISTOR................................................................................9
4.0 MAINTENANCE GUIDE..................................................................................................10
4.1 RED OBSTRUCTION LIGHTING........................................................................10
4.2 L-864 LAMP REPLACEMENT.............................................................................10
4.3 LAMP REPLACEMENT.......................................................................................10
4.4 L-864 CONTROLLER..........................................................................................11
4.4 PHOTOCELL.......................................................................................................11
5.0 MAJOR COMPONENTS LIST ........................................................................................12
6.0 SUGGESTED SPARE PARTS LIST...............................................................................13
WARRANTY & RETURN POLICY
RETURN MERCHANDISE AUTHORIZATION FORM (RMA)

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APPENDIX
CHASSIS LAYOUT................................................................................................1113-R
SCHEMATIC LAYOUT...........................................................................................1113-S
TROUBLE SHOOTING FLOW CHART..................................................................1113-F
PHOTOCELL HOUSING DETAIL ......................................................................... 100239
TOWER LIGHTING KIT 151’ TO 200’....................................................................260-11
...............................................................................................................................260-13
TOWER LIGHTING KIT 201’ TO 350’....................................................................260-12
...............................................................................................................................260-14
OL-1 LIGHT LEVEL DETAIL................................................................................. 100188
L-810 OL-1 SINGLE OBSTRUCTION LIGHT ....................................................FM10018
L-810 OL-1 SINGLE OBSTRUCTION LIGHT DETAIL.......................................... 279-OL
L-810 OL-1 WIRING DETAIL...................................................................................274-S
L-864 FM 300 MM BEACON..............................................................................FM10017
L-864 FM 300 MM BEACON....................................................................................275-B
L-864 FM 300 MM WIRING DETAIL........................................................................273-B
LOAD BALANCE RESISTOR DETAIL.....................................................................276-R
JUNCTION BOX DETAIL...................................................................................... 100089

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C:\Documents and Settings\esalazar\Local Settings\Temporary Internet Files\OLK1\AA1M Rev 033103.doc
Oct 1998 Rev 06/02/99 – 09/10/99 – 05/27/00
Rev 03/31/03 (TWR Logo & reformatted)
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1.0 GENERAL INFORMATION
The TWR Model AA1-M Controller is for A1 lighting of towers 151’ to 350’ above ground
level (AGL) in accordance with the Federal Advisory Circular 70/7460-1K. One (1) beacon
should be placed at the top of the structure. Three(3)obstruction lights should be placedat
the mid-point with respect to overall tower height.
The flash rate of the beacons is 30 per minute. The sidelights burn steady.
A by-pass switch (SW1) allows the controller to be turned on during daylight hours without
covering the photocell. This is particularly helpful since the controller can be mounted
indoors while the photocell is outdoors. SW1 can be operated by turning “on” the toggle
switch mounted on the panel of the controller.
The beacon requires two (2) 620 watt or two (2) 700 watt, 120V bulbs. The use ofany other
bulb may give a false beacon lamp burnout alarm. TWR recommends that you use only
these bulbs. Do not try to use 130V bulbs. Each sidelight requires (1) 116 watt, 120V bulb
(620PS40P, 700PS40P and 116A21TS).
The photocell is the tree (3) blade, twist to lock, type.
Power supplied to the controller shall be 120V, 50/60 Hz.
The controller housing is rated at NEMA 4X. It is suitable for indoor or outdoor mounting.
Controller functions that are monitored by remote alarms in the form of dry contact closures
(Form C) are as follows:
POWER FAILURE Monitors 120V AC to the controller. Alarms in the event of
power failure or tripped circuit breaker.
LIGHTS “ON” Gives an indication whenever the controller is activated.
BEACON Will give an alarm in the event of one (1) or both bulbs failing
or flasher stalling.
FLASHER FAILURE Will give an alarm in the event of flasher failure.
OBSTRUCTION LIGHTS Will give an alarm when one (1) of three (3) sidelights fail.

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C:\Documents and Settings\esalazar\Local Settings\Temporary Internet Files\OLK1\AA1M Rev 033103.doc
Oct 1998 Rev 06/02/99 – 09/10/99 – 05/27/00
Rev 03/31/03 (TWR Logo & reformatted)
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2.0 INSTALLATION
WARNING DANGER!!!
THIS SYSTEM OPERATES AT HIGH VOLTAGE LEVELS THAT COULD BE LETHAL TO
SERVICE PERSONNEL. ALL INSTALLATION AND MAINTENANCE WORK SHOULD
BE DONE BY QUALIFIED SERVICE PERSONNEL ONLY. WHEN PERSONNEL IS
INSTALLING SYSTEM OR PERFORMING MAINTENANCE ON THIS SYSTEM, MAKE
SURE THE POWER IS TURNED OFF AT THE SERVICE BREAKER PANEL!!
READ AND UNDERSTAND THE THEORY OF OPERATION AND ITS SAFETY
MESSAGES BEFORE ATTEMPTING INSTALLATION/MAINTENANCE OF THIS
SYSTEM. DO NOT ATTEMPT TO DEFEAT THE INTERNAL SAFETY SWITCHES IN THE
CONTROLLER AND BEACON!!
2.1 POWER SUPPLY CONTROL CABINET MOUNTING
2.1.1 The power supply control cabinet can be located at the base of thestructure
or in an equipment building. Mounting footprints are shownon Drawing 113-
R. Power wiring to the control cabinet should be in accordance with local
methods and National Electrical Codes (NEC).
2.1.2 If the control cabinet is mounted inside an equipment building, the photocell
should be mounted vertically on ½” conduit outside the building above the
eaves facing north. Wiring from the photocell socket to the control cabinet
should consist of one (1) each, red, black and white wires. The white wire is
connectedtothe socket terminal marked “COM”,theblack wire is connected
to the socket terminal marked “B”, and the red wire is connected to the
socket terminal marked “R”. These socket connections are made by using
.25’ quick connect terminals, which must becrimped to the wires. As above,
the photocell should be positioned so that it does not “see” ambient light,
which would prevent it from switching to the nightmode.
2.1.3 If thecontrol cabinet is mounted outside anequipment building,thephotocell
should be mounted vertically on ½” conduit so the photocell is above the
control cabinet. Care must be taken to assure that the photocell does not
“see” any ambient light that would prevent it from switching into the
nightmode. The photocell wiring is the same as in 2.1.1.
2.1.4 The wiring from the photocell, the service breaker, the red incandescent
beacon, and the sidelights should enter the control cabinet through the
watertight connectors in the bottom of the cabinet. Inside the cabinet, the

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connections will be made on the terminal strips and circuit breakers located
at the bottom of the chassis. These connections are made as follows:
2.2 EXTERNAL PHOTOCELL WIRING (Refer to Drawing 1113-R)
2.2.1 Connect the BLACK wire from the photocell to terminal block TB2 marked
“L”.
2.2.2 Connect the RED wire from the photocell to terminal block TB2 marked
“SSR”.
2.2.3 Connect the WHITE wire from the photocell to terminal block TB2 marked
“N”.
2.3 POWER WIRING (Refer to Drawing 1113-R)
2.3.1 Power wiring to the control cabinet should be in accordance with local
methods and National Electrical Codes (NEC).
2.3.2 Circuit breaker needs to be rated at 20 amps.
2.3.3 Connect incoming 120V AC line to terminal block TB1 marked “L”.
2.3.4 Connect the neutral wire(s) to one (1) of the terminal blocks on TB1 marked
“N”.
2.3.5 Connect the AC ground to the aluminum mounting plate.
2.4 RED BEACON, SIDELIGHT and LOAD BALANCE RESISTOR WIRING (Refer to
Drawings 1113-R, 260-11 through 260-14 and 276-R)
Install wiring between the controller to the beacon utilizing either strobe cable or
conduit method. Refer to Drawings 1113-R, 260-11 through 260-14 and 276-R, for
installation of light kits. Following these requirements,installinglightkits will require
lifting of the cable by the supplied cable grip or conduit to affix to the tower. Always
work safely and adhere to all OSHA Safety Guidelineswhen lifting wiring or working
on the structure or tower itself. It is the installer’s responsibility toinstall the lighting
kit in a safe manner. Installers can request from OSHA their requirements 29CFT
1926.21, and 20CFR 1926.105 to ensure compliance to regulations.
NOTE: On occasion, a set of custom lighting kit drawing may be specifically
requested by a customer and installed in this manual. Incases such as these,
the drawings will proceed the manual if a conflict occurs.
2.4.1 Connect the BLACK wire from the beacon to the circuit breakermarked “B”.

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Oct 1998 Rev 06/02/99 – 09/10/99 – 05/27/00
Rev 03/31/03 (TWR Logo & reformatted)
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2.4.2 Connect the RED wire from the sidelight group to the circuit breaker marked
“S”.
2.4.3 Connect the BLACK wire from the Load Balance Resistor (optional) to the
circuit breaker marked “R”.
2.4.4 Connect the NEUTRAL wire(s) to one of the terminal blocks on TB1 marked “N”.
WARNING DANGER!!!
THIS SYSTEM OPERATES AT HIGH VOLTAGE LEVELS THAT COULD BE
LETHAL TO SERVICE PERSONNEL. ALL INSTALLATION AND MAINTENANCE
WORK SHOULD BE DONE BY QUALIFIED SERVICE PERSONNEL ONLY.
WHEN PERSONNEL IS INSTALLING SYSTEM OR PERFORMING
MAINTENANCE ON THIS SYSTEM, MAKE SURE THE POWER IS TURNED OFF
AT THE SERVICE BREAKER PANEL!!
READ AND UNDERSTAND THE THEORY OF OPERATION AND ITS SAFETY
MESSAGES BEFORE ATTEMPTING INSTALLATION/MAINTENANCE OF THIS
SYSTEM. DO NOT ATTEMPT TO DEFEAT THE INTERNAL SAFETY SWITCHES
IN THE CONTROLLER AND BEACON!!
2.5 RED BEACON AND SIDELIGHT ALARM WIRING (Refer to Drawing 1113-R)
2.5.1 Alarm relays K1-K3, and alarm Modules M1 and M4,are provided
for independent contact closures for: Power Failure, Lights “ON”,
Beacon Flasher Failure, Beacon Lamp Burnout and Sidelight
Lamp Burnout.
2.5.2 Alarm wiring: To utilize all of the red light alarms, the customer
will need five (5) pair of wires to interface with his alarm device.
One (1) wire from each of the five (5) pair will terminate at the
points marking common (C). The remaining wire from each
pair will terminate as follows:
2.5.2.1 Power Failure Alarm: Connect to relay K1,
terminal #3, for normally open (OR) terminal #6, for normally
closed monitoring.
2.5.2.2 Lights “ON” Alarm: Connect to relay K2, terminal
#3, for normally open (OR) terminal #6, for
normally closed monitoring.
2.5.2.3 Beacon Flasher Failure: Connect to relay K3,

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terminal #6, for normallyopen(OR) terminal #3, for
normally closed monitoring.
2.5.2.4 Beacon Lamp Burnout: Connect to Module M1,
terminal T6, for normally open (OR) terminal T7,
for normally closed monitoring.
2.5.2.5 Sidelight Lamp Burnout: Connect to Module M4,
terminal T5, for normally open (OR) terminal T6,
for normally closed monitoring.
2.5.3 Alarm testing: To test alarms, follow the procedures using an “ohm” meter between
alarm common and alarm pints.
2.5.3.1 Power Failure: Pull circuit breaker at electrical panel.
2.5.3.2 Lights “ON”: Operate photocell by-pass switch (SW1) or cover the
photocell. NOTE: (Indication will be delayed 8 – 10 seconds for all the
beacon and sidelight relays to position themselves.)
2.5.3.3 Beacon and Sidelights: Trip circuit breakers on the controller panel.

AA1-M CONTROLLER
C:\Documents and Settings\esalazar\Local Settings\Temporary Internet Files\OLK1\AA1M Rev 033103.doc
Oct 1998 Rev 06/02/99 – 09/10/99 – 05/27/00
Rev 03/31/03 (TWR Logo & reformatted)
9
3.0 THEORY OF OPERATION
3.1 THE POWER SUPPLY
120V AC enters the controller from the circuit breaker panel. Lines sit at the PRD,
waiting to be switched, and also keeps the power failure relay K1 energized. When
the 102FAA photocell is activated, line energizes the coil of the PRD and K2 “Lights
On” relay. This also can be accomplished by using the photocell by-pass switch
(SW1).
3.2 SIDELIGHTS
Line LD is sent through ModuleM4, which is acurrent sensing module for sidelights.
Each SCR430T monitors one (1) level of sidelights, and will provide a contact
closure along a visual indication of one (1) or more lamps fail.
3.3 BEACON
Line LDB is sent to Modules M1, M2 and M3. Module M2 is the primary flasher for
the beacon, which provides control voltage to Module M3, which is an auxiliary
flasher for the load balance resistor. The output of Module M2 is sent through the
current sensing Module M1 to the circuit breaker output “B”. If Module M1 detectsa
lamp burnout, then that module would provide a contact closure along with avisual
indication for the lamp circuit.
Relay K3 is a flasher failure relay for the beacon. If Module M1 detects a flasher
failure, then that module would provide voltage to relay K3, which would provide a
contact closure alone with a visual indication for that beacon circuit.
3.4 LOAD BALANCE RESISTOR
The output of Module M2 (pin #1) is sent to Module M3 for timing purposes. Module
M3 output (pin #1) will operate alternately to the primary flasher’s output. The load
balance resistor (optional) will only be on between flasher to the beacon toeventhe

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Oct 1998 Rev 06/02/99 – 09/10/99 – 05/27/00
Rev 03/31/03 (TWR Logo & reformatted)
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current draw on the generator system.